Sock with shoe-like properties and method for making the sock

ABSTRACT

A footwear article may include a layer coupled to the sock in the sole area of the sock, a heel cushion coupled to the layer in the heel area of the sock, and a polymer material added to the sole area, the lower sides, the lower front side, and the lower rear side of the sock. The polymer material may encompass the layer in the sole area of the sock and the heel cushion. A method for manufacturing a footwear article may include steps of placing a sock on a last; coupling a layer to the sock in the sole area; coupling a heel cushion to the layer in the heel area; placing a heel-area piece and a ball-area piece in a bottom portion of a mold; introducing the last and the sock into the mold; closing the mold; and injecting a polymer material into the bottom portion of the mold, so that the polymer material flows to the sole area, and the lower sides of the sock.

BACKGROUND

This disclosure relates in general to an article of footwear, and a method for making the article, for a sock that can be used as a shoe. The sock is particularly suited for long-term wear with comfort in conditions involving water and food spillage, such as a restaurant kitchen.

Footwear that combines properties of shoes and socks typically have an overmolded sole on a textile sock or have a shoe structure with an upper formed of one or more knit layers combined with other layers. For example, U.S. Pat. No. 9,532,624 shows an example of a two-layer sock structure with a PVC overmolding, which is only useful as a sock or slipper and not for the more rigorous conditions required of a shoe. As another example, U.S. Pat. No. 8,209,883 discloses in FIGS. 570-575 a knit upper with an overmolded plastic material, that may be assembled with an outsole.

Embodiments of the present disclosure include a simplified manufacturing method to produce footwear that fits in a manner similar to socks, slippers, or comfort sandals but with protection from typical environmental concerns, such as liquid or wet materials. The method may provide improved production rate at lower cost of footwear that is waterproof, breathable, flexible, slip-resistant, and sturdy enough to be used as a shoe.

SUMMARY

According to an aspect of the present disclosure, a method for producing a shoe sock may include providing a sock and a last and placing the sock on the last. The method may further include steps of applying a fabric layer over a sole area of the sock and a heel cushion to a heel area of the fabric layer, and adhering the fabric layer to the sock and adhering the heel cushion to the fabric layer.

According to an aspect of the present disclosure, a shoe sock may include a sock and added structure, wherein the added structure includes a fabric layer adhered over a sole area of the sock and a heel cushion adhered to a heel area of the fabric layer.

Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating various embodiments, are intended for purposes of illustration only and are not intended to necessarily limit the scope of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is described in conjunction with the appended figures:

FIG. 1 is a side pictorial view showing an example of a sock for use with embodiments of the present disclosure, the sock providing a three-layer construction of a waterproof, breathable layer between two knit layers.

FIG. 2 is a side pictorial view of a last according to the present disclosure, the last providing a structural support for the sock of FIG. 1 to carry out one or more of the methods described herein.

FIG. 3 is a view from beneath of the last of FIG. 2 .

FIG. 4 is a side pictorial view of a sock as in FIG. 1 in place on the last of FIGS. 2-3 .

FIG. 5 is a side pictorial view similar to FIG. 4 , in this case showing the sock in phantom outline and showing, in exploded format, a thin layer to be added over the sole area of the sock and a thicker piece to be added to the heel area of the sock.

FIG. 6 is an overhead view of an example of the thin layer of FIG. 5 .

FIG. 7 , is an overhead view of an example of the thicker piece of FIG. 5 .

FIG. 8 is a side pictorial view of the sock and additional structures of FIGS. 1-7 and two additional rubber pieces that are placed in the mold, one beneath the heel area and one beneath the ball area.

FIG. 9 is a view from beneath the sock and additional structures of FIG. 8 showing the placement in the mold of the additional pieces relative to the ball area and the heel area of the sock.

FIGS. 10 a-i are diagrams of the sock with the added structures depicted from both sides and above and below, with cross-sectional depictions from the ball, midsole, and heel areas of the sock and structure.

FIGS. 11 a-c are close-up diagrams of the sock with the added structures depicted from both sides and below.

FIG. 12 is a side pictorial view of the complete article for the sock with an overmolded structure added.

In the appended figures, similar components and/or features may have the same reference number or the same number with a letter suffix.

DETAILED DESCRIPTION

The following detailed description of some exemplary embodiments of the present disclosure do not limit the scope, applicability, or configuration of the other embodiments that will be understood from the present disclosure. The ensuing description will provide those skilled in the art with an enabling description not only for the exemplary embodiment but also other embodiments within the scope of the present disclosure. It is understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope as set implementing forth in the appended claims.

As shown in FIGS. 1-12 , an article 100 fora sock with shoe-like properties, i.e., a shoe-sock, in accordance with the present disclosure, may be constructed from a sock, such as a three-layer, waterproof sock 102 (FIG. 1 ) with the addition of structure 104 generally in the sole area 106, lower sides 108, and lower front side 110 and lower rear side 112 of sock 102.

Sock 102 may be any type of sock as best suited to the particular application for shoe sock 100. Sock 102 may be a single-layer, non-waterproof sock with structure 104 added to that. For applications of shoe-sock 100 in wet environments, both indoor and outdoor, sock 102 may be a multi-layer sock, such as a 3-layer sock. Such a sock may include a knit interior lining made of any fabric suitable to the particular application. Generally the fabric of the interior lining is selected for comfortable contact directly with the user's foot. The sock may additionally include an exterior layer, formed for example, of a knit fabric. Typically the interior lining and the exterior layer are coextensive from a toe area to the opening where the user's ankle/leg is with the sock in place. The sock may additionally include a middle layer, which may also be coextensive with the other layers, although each layer may be larger or smaller than the others as best suited to a particular application for the shoe sock. For example, the middle layer may extend over less of an area as compared to the other layers, for example, by not extending as far up the leg of the wearer. The middle layer may be a waterproof membrane, and may also be breathable.

A knit fabric exterior layer for sock 102 is suited for the addition of structure 104 in accordance with the methods described herein although other types of exterior layers may alternatively be used. Structure 104 typically is added by bonding processes, which may include one or both of self-adhesive methods and/or molding methods.

An embodiment of a method to add structure 104 begins with placing sock 102 on a last 114, as may be seen in FIGS. 1-5 and 8 . Sock 102 defines, as noted above, sole area 106, and area 106 further includes a toe area 116, a ball area 118, a midsole area 120, and a heel area 122. With sock 102 on last 114, a layer 124 may be added at sole area 106.

As best seen in FIG. 6 , layer 124 typically has a layout that conforms to the shape of a wearer's foot sole and/or sole area 106 of sock 102. Layer 124 may be attached by any suitable process, for example, by being provided with a self-adhesive surface 126 for contact adhesion to sole area 106. Layer 124 may be formed of any material suited to a particular application, such as a breathable, non-woven fabric.

Addition of sole-covering layer 124 and a heel cushion 128 are illustrated in FIG. 5 . Typically heel cushion 128 is added on an outer surface 130 of layer 124 or alternatively may be placed between sock 102 and layer 124. Heel cushion 128 may be attached by any suitable process, for example, by being provided with a self-adhesive surface 132 for contact adhesion to either layer 126 or sock 102. Heel cushion 128 may be formed of any material suited to a particular application, such as an ethylene-vinyl acetate (EVA) material. Typically, heel cushion 128 is sized and shaped to provide cushioning in the heel area or, alternatively, cushion 128 may extend wholly or partially along the whole bottom of the sock, for example, to be the same size as layer 124, or, as another example to be about half the size of layer 124 and to extend from the heel to the arch area.

Additional structure 104 may include additional pieces, such as one or more rubber pieces and a polyurethane portion. The pieces 134, 136 may be added by any suitable process, for example, by a molding process, which also may add the polyurethane portion.

A mold 138, as shown in FIG. 8 , may include a bottom portion 140 and upper portion 142, which may be selectively separated and closed together. Mold portions 140 and 142 meet at a seam 146. Sock 100, on last 104, may have layer 124 and cushion 128 adhered and pressed in place in preparation for placement in mold 138. Note that, as shown in FIG. 8 , layer 124 may conform to the shape of last 114.

Typically, heel-area piece 134 and ball-area piece 136 are first placed in bottom portion 140 of mold 138 prior to sock 102 with adhered layer 124 and cushion 128 being introduced to mold 138. Pieces 134 and 136 may be formed of any material structure suited to the particular application of shoe sock 100, e.g., they may be rubber, or otherwise provided with an outer surface that is abrasion and slip resistant. Alternatively, one or both of pieces 134 and 136 may be attached by another bonding process.

For a molding process, as shown in FIGS. 8 and 9 , pieces 134 and 136 may be placed in bottom 140 of mold 138. Sock 102 with layer 124 and cushion 128, may be placed in mold 138, and held there with a suitable amount of downward force. An upper portion 142 of mold 138 may applied over sock 102 and mold bottom 140 and a suitable seal and/or pressure applied for the molding process.

A liquid material 148 may then be poured and/or injected into mold 138, for example, from beneath bottom 140 as indicated by arrow 144 in FIG. 8 . Any suitable material may be used, for example a polymer material such as a polyurethane. A liquid material 148, such as polyurethane, when poured or injected into the mold, may be expected to flow into and fill all empty areas within the mold. As polyurethane evaporates and solidifies, it may bond with the sock and other materials in the mold since polyurethane itself has characteristics of glue.

When liquid material 148, such as polyurethane, enters mold 138 under suitable pressure, the material will push up the lower surface of sock 102 along with layer 124 against the bottom of last 114. This pressure may provide for the top of material 148, that is, the part of material 148 that is pushing up on layer 124 and/or sock 102, to conform in shape to the bottom of last 114.

Polyurethane material 148 is typically allowed to cure in the mold for a suitable time. As noted above, material 148 may be conformed in shape to the bottom of last 114 and may retain that shape in curing. The mold portions 140, 142 may then be separated and shoe sock 102 removed from mold 136. Shoe sock 102, after removal from mold 138 may additionally require the trimming of edges and any other unwanted portions left over from the molding process.

The method of producing shoe-sock 100 as described above may produce an article for footwear with improved arch support and cushioning for the entire foot length. Shoe-sock 100 is made waterproof breathable, light-weight, flexible, and slip resistant. The method may be carried out, for example, by three persons: a first person to place sock 102 on last 114 and adhere layer 124 and cushion 128 to sock 102, to place pieces 134, 136 in mold 138, and then introduce the sock and last into the mold and to operate the mold to add the polyurethane material 148; a second person to pull out the last and shoe-sock from the mold and to trim excess material; and a third person to package the shoe-socks.

Shoe-sock 102 in embodiments of the present disclosure provide improved comfort resulting from factors that include exact fitting and shape of the lower surface of last 114. That is, last 114 in the shape of a typical foot, and is provided in a range of sizes, e.g., the sizes and half-sizes as are typically provided for shoes. Alternatively, the shoe-socks may be provided in whole sizes only, with an effect of reducing the inventory burden for manufacturers, wholesalers, and retailers.

As shown in FIGS. 10 a-i , shoe-sock 100 may be provided with a tread on its lower surface for improved traction and wear. As shown in FIG. 11 a-c , in addition to the tread, the lower surface may include an area for indicating information about the shoe-sock, such as brand, model, and/or other general or specific information.

As illustrated in the drawings and described above, sock 102 may be of any cut as desired for a particular application of shoe-sock 100. For example, as shown in FIG. 1 , a mid-cut shape may be used for sock 102 or a low-cut shape or other shape may be used as shown in other Figs.

Specific details are given in the above description to provide a thorough understanding of the embodiments. However, it is understood that the embodiments may be practiced without these specific details. For example, structures may be shown in simplified diagrams in order not to obscure the embodiments in any detail. In other instances, well-known processes, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.

While the principles of the disclosure have been described above in connection with specific apparatuses and methods, it is to be clearly understood that this description is made only by way of example and not as limitation on the scope of the disclosure. 

1. An article for footwear, the article comprising: a. a sock defining a sole area, a pair of lower sides, and a lower front side and a lower rear side; b. a layer coupled to the sock in the sole area of the sock, the layer defining a heel area; c. a heel cushion coupled to the layer in the heel area of the sock; d. a polymer material added to the sole area, the pair of lower sides, the lower front side, and the lower rear side of the sock, wherein the polymer material encompasses the layer in the sole area of the sock and encompasses the heel cushion.
 2. The article for footwear of claim 1 further comprising a heel-area piece that is coupled to the sock by the polymer material.
 3. The article for footwear of claim 1 further comprising a ball-area piece that is coupled to the sock by the polymer material.
 4. The article for footwear of claim 1 wherein the sock is waterproof.
 5. The article for footwear of claim 4 wherein the sock include a waterproof membrane between two knit layers.
 6. The article for footwear of claim 5 wherein the waterproof membrane is breathable.
 7. The article for footwear of claim 1 wherein the layer in the sole area is coupled to the sock by a self-adhesive surface on the layer.
 8. The article for footwear of claim 1 wherein the heel cushion is attached to the layer by a self-adhesive surface on the heel cushion.
 9. The article for footwear of claim 1 wherein the polymer material is polyurethane.
 10. The article for footwear of claim 1 further comprising a rubber heel-area piece and a rubber ball-area piece, wherein the rubber pieces are coupled to the sock by the polymer material.
 11. The article for footwear of claim 1 wherein the layer coupled to the sock in the sole area of the sock is substantially made of a nonwoven fabric.
 12. A method for manufacturing an article for footwear, the method comprising steps of: a. placing a sock on a last, wherein the sock defines a sole area, a pair of lower sides, and a lower front side and a lower rear side; b. coupling a layer to the sock in the sole area of the sock, the layer defining a heel area; c. coupling a heel cushion to the layer in the heel area of the sock; d. providing a mold configured to receive the last and the sock, the mold defining an upper portion and a bottom portion; e. placing a heel-area piece and a ball-area piece in the bottom portion of the mold; f. introducing the last and the sock, with the layer in the sole area and the heel cushion, into the mold; g. closing the mold; and h. injecting a polymer material into the bottom portion of the mold, the polymer material flowing to the sole area, the pair of lower sides, the lower front side, and the lower rear side of the sock.
 13. The method of claim 12 further comprising a step of removing the article from the mold and trimming any excess polymer material.
 14. The method of claim 12 wherein the step of coupling the layer in the sole area to the sock uses a self-adhesive surface on the layer.
 15. The method of claim 12 wherein the step of coupling the heel cushion to the layer uses a self-adhesive surface on the heel cushion.
 16. The method of claim 12 wherein the polymer material is polyurethane.
 17. The method of claim 12 wherein the heel-area piece and the ball-area piece are formed substantially of rubber.
 18. The method of claim 12 wherein the layer coupled in the sole area of the sock is formed substantially of a non-woven fabric.
 19. The method of claim 12 wherein the heel cushion is formed substantially of ethylene-vinyl acetate (EVA). 